Aircraft Materials,

Construction and Repair

Sheet Metal & Rivets
Sheet Metal

 Sheet metal is metal formed by an industrial process into

thin, flat pieces. Sheet metal is one of the fundamental
forms used in metalworking, and it can be cut and bent
into a variety of shapes.
 Sheet metal is being used in the production and
fabrication of aircraft components, with different alloys
and characteristics to provide a much efficient use to
every specific component.
Aircraft Rivets

 While a number of methods are available for joining metal

parts, few are ideal for joining aluminum sheets. The
most common technique of joining sheets of aluminum is
riveting.
Aircraft Rivets

 To aid manufacturers in standardizing riveting techniques,

the National Advisory Committee for Aeronautics, or
NACA, established a set of standards for riveting aircraft
and aerospace vehicles. When riveting is conducted to
these standards, the process is referred to as NACA
riveting.

 What is A Rivet?
Aircraft Rivets

 A rivet is a metal pin with a formed

head on one end. A rivet is inserted
into a drilled hole, and its shank is
then deformed by a hand or
pneumatic tool. Rivets create a
union at least as strong as the
material being joined.
Rivets Specification
AMS Aeronautical Material Specification
AN Air Force - Navy
AND Air Force - Navy Design
AS Aeronautical Standard
ASA American Standard Association
ASTM American Society for Testing and Materials
MS Military Standard
NAF Naval Aircraft Factory
NAS National Aerospace Standard
SAE Society of Automotive Engineers
Solid Shank Rivets

 Solid shank rivets are generally used in

repair work. They are identified by the
kind of material of which they are
made, their head type, size of shank,
and their temper condition. The
temper designation and strength are
indicated by special markings on the
head of the rivet.
Solid Shank Rivets
Solid Shank Rivets
Solid Shank Rivets
 A proper sized pilot hole should be drilled
Rivet Best Common Hole
size drill drill size
3/32 #40 7/64 0.096
1/8 #30 9/64 0.128
5/32 #21 11/64 0.159
3/16 #11 13/64 0.191
7/32 #10 15/64 0.225
1/4 #F 17/64 0.257
5/16 #P 21/64 0.323
3/8 #W 25/64 0.386
7/16 29/64 29/64 0.453
1/2 33/64 33/64 0.516
Rivet Pilot Hole Drill Size
Rivet Codes

 Rivets are given part codes that indicate their size, head
style, and alloy material. Two systems are in use today,
the Air Force - Navy, or AN system, and the Military
Standards 20 system, or MS20. While there are minor
differences between the two systems, both use the same
method for describing rivets.

 AN470AD-4-5.
 Rivet Codes (AN470-AD4-5)

 The first component of a rivet part number denotes the numbering system
used.
 The second part of the code is a three-digit number that describes the style
of rivet head. The two most common rivet head styles are the universal
head, which is represented by the code 470, and the countersunk head,
which is represented by the code 426.
 Following the head designation is a one or two-digit letter code
representing the alloy material used in the rivet.
 After the alloy code, the shank diameter is indicated in 1/32 inch
increments and the length in increments of 1/16 inch.
Rivet Codes
Rivet Head Design

 Solid shank rivets are available in two

standard head styles:
 Protruding head - an(470) universal
 Flush Head - an(426) countersunk
Protruding head

 Round head rivet (AN430) was used

extensively on aircraft built before
1955,
 Flat head rivet(AN442) was widely
used on internal structures.
Flush head

 Countersunk (AN426) developed to

streamline airfoils and permit a
smooth flow over an aircraft's wings
or control surfaces.
Flush head

 Dimpling is a process that mechanically "dents" the sheets

being joined to accommodate the rivet head.
 countersinking is a process in which the metal in the top
sheet is cut away in the shape of the rivet head.
 Sheet thickness and rivet size determine which method is
best suited for a particular application.
Flush head
Flush head

 Joints utilizing countersunk rivets generally lack the

strength of protruding head rivet joints.
 Portion of the material being riveted is cut away to
allow for the countersunk head.
 When riveted, the gunset may not make direct contact
with the rivet head if the rivet hole was not
countersunk or dimpled correctly, resulting in the rivet
not expanding to fill the entire hole.
Flush head

 To ensure head-to-gunset contact, it is recommended that

countersunk heads be installed with the manufactured
head protruding above the skin's surface about .005 to
.007 of an inch.
 Microshaver – a rotary cutter shaves the rivet head flush
with the skin, leaving an aerodynamically clean surface.
Flush head

 Crown Flush Rivets – are rivets

that have a slightly crowned
head to allow full contact with
the gunset.
Rivet Alloys

 Most aircraft rivets are

made of an aluminum alloy.
The type of alloy is
identified by a letter in the
rivet code and by a mark on
the rivet head itself.
1100 Aluminum (A)

 These rivets made of pure aluminum have no identifying

marks on their manufactured head and are designated by
the letter A in the rivet code.
 The 1100 rivet is driven cold, and therefore, its shear
strength increases slightly as a result of cold working
2117 aluminum alloy (AD)

 The most widely used for manufacturing and maintenance

of modern aircraft, have a dimple in the center of the
head and are represented by the letters AD in rivet part
codes. Because AD rivets are so common and require no
heat treatment, they are often referred to as "field
rivets”.
 The main advantage for using 2117-T3 for rivets is its high
strength and shock resistance characteristics.
5056 Aluminum alloy (B)

 Some aircraft parts are made of magnesium. Magnesium

structures are riveted with 5056 rivets which contain
about 5 percent magnesium. These rivets are identified by
a raised cross on their heads and the letter B in a rivet
code.
 The maximum shear strength of an installed 5056H32 rivet
is 28,000 psi.
2017 aluminum alloy (D)

 These rivets are identified by a raised dot in the center of

their head and the letter D in rivet codes. because d-
rivets are so hard they must be heat treated before they
can be used.
 rivets made of 2017 can be kept in an annealed condition
by removing them from a quench bath and immediately
storing them in a freezer. because of this, d-rivets are
often referred to as ice box rivets. These rivets become
hard when they warm up to room temperature and may
be reheat-treated as many times as necessary without
impairing their strength.
2024 ALUMINUM ALLOY (DD)

 DD-rivets are identified by two raised dashes on their

head. Like D-rivets, DD-rivets are also called icebox rivets
and must be stored at cool temperatures until they are
ready to be driven.
7050 Aluminum alloy (E)

 A new and stronger rivet alloy was developed in 1979

called 7050T73. The letter E is used to designate this
alloy, and the rivet head is marked with a raised circle.
7050 alloy contains zinc as the major alloying ingredient
and is precipitation heat-treated.
 This alloy is used by the Boeing Airplane Company as a
replacement for 2024T31 rivets in the manufacture of the
767 wide body aircraft.
Rivet alloys

ALLOY LETTER HEAD MARKING DRIVEN CONDITION

1100 A PLAIN 1100-F

2117 AD DIMPLE 2117T3
5056 B RAISED CROSS 5056H32
2017 D RAISED DOT 2017T31
2024 DD TWO RAISED DASHES 2024T31
7050 E RAISED RING 7050T73
Rivets spacing

 It is important when making a riveted repair that the

rivets be installed in such a way that they will develop the
maximum strength from the sheet metal. This means the
spacing between rivets and the distance they remain from
the edge of the material cannot be closer than minimum
specifications.
Rivets spacing

 Edge distance - also called edge margin by some

manufacturers, is the distance from the center of the first
rivet to the edge of the sheet.
 Universal Rivets = 2D
 Countersunk rivets = 2.5D
Rivets spacing

 Rivet pitch - is the distance between the centers of neighboring rivets in

the same row. Rivet spacing on parts that are subjected to bending
moments is often closer to the minimum spacing to prevent buckling of
the skin between the rivets.
 Universal Rivets = 3D
 Countersunk rivets = 4D

 For protruding - One-and three-row layouts have a minimum pitch of 3

rivet diameters, a two-row layout has a minimum pitch of 4 rivet
diameters
 For countersunk - One-and three-row layouts have a minimum pitch of
3.5 rivet diameters, a two-row layout has a minimum pitch of 4.5 rivet
diameters
Rivets spacing

 Rivet gage – also known as Transverse pitch, is the

perpendicular distance between rivet rows. It is usually 75
percent of the rivet pitch. The smallest allowable
transverse pitch is 2.5 rivet diameters.
example

MATERIAL : 0.040 CLAD ALUMINUM ALLOY

RIVET : MS20470AD4-4
REQUIRED RIVETS : 11
FIRST ROW : 6
SECOND ROW : 5